Apparatus for making concrete logs and the like



0. O. EMERY July 11, 1961 APPARATUS FOR MAKING CONCRETE LOGS AND THE LIKE Filed July 1, 1959 INVENTOR: OL/A/ 0. Emmy 2,991,534 APPARATUS FOR MAKING CONCRETELOGS Olin O. Emery, Jackson, .Wyo. (Rte. 2, Box 267, Longmont, Colo.) Filed July 1, 1959, Set. No.'824,403 3 Claims. (Cl. 25 -121) This invention relates to the formation of precast building elements and more. especially. to an apparatus for making prefabricated concrete. logs employed in constructing the framework of buildings.

In the construction of cabins and other building structures from prefabricated materials, the various elements must be of such length and shape as required to provide the usual window and door openings, as well as to provide the desired exterior appearance of the finished structure. I have found concrete logs to be especially adapted for the construction of prefabricated cabins on account of the permanent character of this material, and the manner in which the mortar lends itself to the formation of various shapes and sizes.

The production of suitable concrete logs, however, is confronted with a number of problems peculiar to log construction. For example, in the corner construction of cabins, the overlapping transversely disposed logs are usually notched, thus diminishing the cross-sectional area and strength at a critical point. Also in such corner construction, the ends of the overlapping logs often extend outwardly beyond the notches in order to enhance the external beauty; but in so doing theseends are cantilevered, thereby imposing an additional bending moment at the notches, which moment must be resisted by the remaining cross section of the log weakened by the notch. Accordingly, particular care must be exercised to work the mortar during the formation of the log notches and adjacent portions so as to provide optimum strength. Furthermore, the cantilevered ends of the logs are fully exposed to view and to weather conditions. Hence, greater care should be taken to provide a pleasing appearance and an outer surface resistant to erosion.

It is therefore an object of this invention to provide an apparatus for making concrete logs which will solve the above-mentioned problems.

It is a further object of this invention to provide a form adapted to cast notched concrete logs of the various shapes, sizes and lengths required .in the. construction of the finished structure.

Some of the objects of the invention having been stated, other objects Will appear as the description proceeds when taken in connection with the accompanying drawings, in which,

FIGURE 1 is an elevation of a portion of abuilding constructed from concrete logs made in accordance with the invention;

FIGURE 2 is a fragmentary view looking at the righthand end of FIGURE 1;

FIGURE 3 is an elevation, with portions broken away, of one form of apparatus employed in casting the concrete logs;

FIGURE 4 is a plan view of FIGURE 3;

FIGURE 5 is a sectional plan view. taken along line line 55 in FIGURE 3;

FIGURE 6 is a transverse sectional view takenralong line 66 in FIGURE 3;

FIGURE 7 is a transverse sectional view taken along line 77 in FIGURE 3;

FIGURE 8 is a transverse sectional view taken along line 88 in FIGURE 3, and

FIGURE 9 is an exploded isometric view showing the manner of supporting an insert within the apparatus.

nited States Patent 0 2,991,534 Patented July 11, 1961 Referring more specifically to the drawings, the numeral 10 broadly designates a building structure composed of logs 11, 12, 13 and 14, which logs are precast in such shapes and lengths as to provide a window or door opening 15 when erected. The log 11 is provided with notches 16 at each end thereof which fit respectively over the ends of two other transversely disposed. logs 11, '12, 13 or 1 4, depending upon its location. The legs 11 have integral therewith outwardly extending cantilevered portions 17 of suitable length to supply the desired ornamental effect. Logs 12, 13 and 14 have similar cantilevered portions 17. The log 12, disposed immediately beneath the uppermost log 11 in FIGURE 1, is provided with a notch 18 in the lower intermediate portion thereof, said notch forming the head of opening 15. Except for notch 18, the log 12 is identical to log 11. The logs 13 are each identical to the end portions of log 11, the inner ends of log 13 being unnotched and terminating at the edge of opening 15. The inner ends of the four logs 13 forms the sidewalls of jambs of the opening. Log 14, disposed at the bottom of the structure shown in FIGURE 1, is provided with a notch '19 in its upper intermediate portion, said notch forming the base or sill of opening 15. The remaining portions of log 14 are identical to log 11. The logs described above are adapted to be produced in accordance with my improved apparatus.

Although round logs are shown in the drawings, it is to be understood that various cross-sectional shapes may be produced, such as square, rectangular, half-round or elliptical shapes, without departing from the spirit of the invention. The invention also contemplates the use of a mortar composed of any viscous or plastic material which will harden subsequent to molding.

The casing or form with which the concrete logs are produced is designated broadly by reference character 22. This casing comprises two elongated concavo-convex sections 23 and 24 secured together in such a manner that their concave faces will combine to provide a cylindrical cavity.. Section 23 has lugs 25 extending radially from the upper and lower edges thereof, which lugs are adapted-to fit face-to-face against similar lugs 26 extending radially from the upper and lower edges of section 24 when the apparatus is in assembled position. A bolt 27 penetrates each pair of lugs 25 and 26 to removably hold the casing sections together.

The concave portions of sections 23- and 24 have convex projections28 and 29 respectively therein, said projections partially'restricting the sizes of the respective concave cross-sections. Projections 28 and 29 are adapted to fit against one another (FIGURES 3 and 5) to form inside the casing a transversely disposed cylindrical segment whose radius is substantially the same as that of the logs 11 through 14. In other words, projections 28 and 29 are adapted to form notches 16 when the logs are cast.

The sections 23 and 24 extend outwardly beyond the abutting projections 28 and 29, and these extended portions combine to form a cavity of circular cross-section conformingto that of the exterior of cantilevered log ends 17.

A closure plate or piston 31 slidably fits in each end of the casing 22, said plate being adjust-ably held in position by means of rod 32. threadably mounted in lateral extension 23a of section 23 (FIGURE 5). A hand wheel 33 is secured on the outer end of rod 32 so that the rod may be rotated to shift plate or piston 31 longitudinally of the casing cavity. The adjustable end plate or piston 31 serves the dual purpose of varying the overall length of a log, and compressing the confined mix- .ducing two of such logs.

ture during the molding operation to provide a mortar of greater density.

A pair of intake openings 34 is provided in the wall of casing 22 opposite the projections 28 and 29, said openings being positioned longitudinally inwardly from the center lines of the projections. Each opening 34 is formed partially in the edge of section 23 and partially in the edge of section 24. p A cover 35 may be employed to close or restrict opening 34 at certain times during the production of a log (FIGURE 6).

In the intermediate portion of the casing 22, means are provided for supporting block members or forms of various shapes and lengths corresponding to the particular log to be produced. This supporting means comprises a pair of bolts 36, each such pair penetrating a pair of semicircular notches 37 and 38 respectively, in the upper and lower edges of sections 23 and 24 (FIGURES 8 and 9). The inner ends of a pair of bolts 36 are embedded in a block or form 39 which is removably supported within the upper portion of the casing, and another pair of bolts 36 removably support a block or form 39 immediately below the upper block. When it is desired to produce a log 12 having a head notch 18 therein, only the lowermost member 39 is retained (FIGURE 3) within the casing. Similarly, in order to produce a log 14 with a base or sill notch 19 therein, only the uppermost block is retained. If logs 11 are to be produced, both the upper and lower blocks 39 are retained within the casing, in which case, space is provided within the form for pro- Finally, to produce a log 11 without any notches in its intermediate portion, both members 39 are removed.

As previously stated, the notched and cantilevered portions of the finished logs are more vulnerable to internal stresses and erosion than other portions, and consequent- 1y, greater care must be exercised to provide optimum strength at these points. One of the functions of the present invention is to eliminate voids and air pockets from the mortar confined adjacent the notches and in the cantilevered portions, thereby producing optimum density and strength.

In the construction of a log, the end plate or piston 31 is first positioned outwardly so that the casing cavity will be somewhat longer than a completed log. The excess length of the casing cavity will depend upon the porosity,

and viscosity of the particular mortar mix employed. The mortar mix is then poured through opening 34 into casing 22. ,At the same time the mix is tamped longitudinally outwardly to deposit it into the end portions. The tamping may be effected by inserting a tamping rod through opening 34. As the casing becomes full, the tamping is continued and at the same time, the end plate or piston 31 is forced inwardly until the column of concrete mortar is reduced to the exact length of the finished log. During such movement of plate or piston 31 an appreciable flow of mortar will occur at the casing restriction opposite projections 28 and 29; and during this flow, air pockets and terials such as concrete and the like comprising, an elongated casing having an interior space of substantially uniform cross-sectional area, a transversely disposed projection extending from the wall of the casing into said space and dividing the casing interior into first and second elongated compartmentsrespectively, said projection providing a restricted opening having a cross-sectional area less than that of saidrinterior space, means for closing the outer end of said firstcompartment, the wall of said first compartment having an access opening therein substantially opposite said restricted opening to thereby permit the second compartment to be filled with a column of mortarmaterials through said two openings, closure means for said access' 'opening, a piston mounted for longitudinal movement in the outer end of said second compartment, said piston having a cross' sectional area substantially the same as that of said interior space, and means including said piston for exerting pressure upon one end of said column of mortar materials to force the other end of the column through said restricted opening, whereby an increased unit pressure will be imparted to the mortar materials while flowing past the restricted opening.

- 2. A casting form'as defined in claim 1 wherein said casing is divided into two sections at a plane passing substantially through the longitudinal center line of the casing, said plane being disposed normal to and bisecting said transverse projection, and means for detachably securing said sections one to the other.

3. A form for casting a notched log from mortar materials such as concrete and the like comprising, an elongated casing having an interior space of substantially uniform cross-sectional area, a transversely disposed projection extending from the wall of the casing into said space and dividing the casing interior into first and second elongatedcompartments respectively, said projection providing a restricted opening having a cross-sectional area less than that of said interior. space, means for closing the outer end of said first compartment, means including an opening in said casing for permitting said second compartment to be filled with a column of mortar materials, closure means for said last-named opening, a piston mounted for longitudinal movement in the outer end of said filled second compartment, said piston having a crosssectional area substantially the same as that of said instricted opening, 'whereby an increased unit pressure will voids will be eliminated by the increased internal pressure;

of limitation, the scope of the invention being set forth in the following claims.

I claim: l. A form for casting a notched log from mortar mabe imparted to the mortar materials while flowing past said restricted opening.

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